I have started
to make my own 1mm foam as it is
either hard to source or too heavy
or really expensive.
I used the old wire cutter method
using a .3mm guitar string and a
12V transformer powered by a car
battery.

I cut my foam by
holding it in place with a sheet
of glass. I use piano wire sticky
taped just a little wider than the
foam to a flat board to give me
the varying height/thickness. All
I do is slide the cutter along the
wire until I get to the other side.
It curls from the heat:

I then flatten it again by sheeting
it in between 2 pieces of glass
and heating it in the oven at 145
celcius for 10 minutes - remove
and let stand till cool. Then I
remove it:

If you use 3mm foam, you end up
with a 1mm sheet and a 1.5mm sheet!

Flat as a tack!

I curved this foam fuse around a
balsa mold and then poured boiling
water from the kettle on it to hold
the shape better:

Here is the fuse. It's for my 12"
Christen Eagle, same shape as the
Micro Pitts - 2 grams AUW including
formers.